Wall module

ABSTRACT

A building block module for construction of vertical walls, panels and the like is described. The block is a tall, free standing hollow core block that reduces the number of horizontal courses of blocks needed to construct a vertical panel. The block has two vertical sidewalls and two open walls and cavity means in the top and at various heights to receive block to block reinforcing means.

United States Patent [191 Slaven 1 WALL MODULE [76] Inventor: Ernest Lynn Slaven, 10632 Morningside, Garden Grove, Calif.

[22] Filed: June 7, 1972 [21] Appl. No; 260,457

[52] U.S. Cl 52/169, 52/436, 52/439, 52/600 [51] Int. Cl. E02d 27/01, E04b 2/26 [58] Field Of Search 52/606, 227, 274, 293, 52/289, 579, 439, 169, 436, 600; 256/19 [56] References Cited UNlTED STATES PATENTS 405,429 6/1889 Missud 52/606 X 881,747 3/1908 Townsend... 256/19 1,186,592 6/1916 Mathews et al.. 52/439 X 1,355,572 10/1920 Ross 52/274 X 1,786,691 12/1930 Belding t 1 52/436 2,027,493 1/1936 Thilborger t 256/19 3,391,507 7/1968 Downing 52/606 X [451 June 25, 1974 3,422,588 l/1969 Stewart, Jr 52/605 R21,905 9/1941 Nielsen et a1. 52/274 X FOREIGN PATENTS OR APPLICATIONS 625.594 8/1961 Canada 52/293 696,831 10/1930 France 52/293 420,097 11/1934 Great Britain 52/293 911.907 5/1954 Germany 52/439 Primary ExaminerAlfred C. Perham Attorney, Agent, or FirmRobert E. Strauss [57] ABSTRACT 10 Claims, 9 Drawing Figures FIG 9 I Cll FIG 8 WALL MODULE DESCRIPTION OF THE INVENTION This invention relates to a building block and, in particular, relates to a block having a hollow or open interior and useful in construction of walls, panels and the like.

Typical masonry construction employs bricks or blocks which are laid up in a plurality of courses until the desired height of the wall fence, vertical panel or the like is reached. Bricks or hollow blocks cast from concrete or cinders are used in this construction, joined together by mortar and reinforced, when necessary, by steel wire, cable or rods which are laid in vertical and horizontal alignment in the wall, panel, fence or the like.

The aforementioned construction is quite tedious, requiring considerable hand labor. A fair degree of skill and training in laying the individual bricks or blocks in proper alignment is required. Tilt-up wall construction, wherein a wall or vertical panel is cast as a slab on a floor and is then tilted upright, moved into place and secured to supporting structure, has been developed to minimize the hand labor and costs of construction. This construction, however, requires substantial investment in equipment and a highly skilled work force. Accordingly, the need for simple, inexpensive means and method for the construction of walls, vertical panels, fences and the like by an inexperienced work force has not yet been satisfied.

It is an object of this invention to provide a precast block for masonry construction.

It is also an object of this invention to provide such a block with a size, shape and configuration that insures accurate alignment of assembled blocks and minimizes the degree of skill necessary in the assembly.

It is an additional object of thisinvention to provide such a block that will minimize the number of horizontal courses which must be laid in construction of a wall, vertical panel, fence or the like.

It is likewise an object of this invention to provide a simple method for the construction of a wall, vertical panel, fence or the like.

Other and related objects will be apparent from the following description of the invention.

l have now found that the aforementioned objects can be attained by a block of particular shape and design as well as a method for its use in vertical wall construction. The block has a bottom, top and sidewalls extending'therebetween defining a body with two continuous sides and two open sides with a height of from 8 to about 36 times greater than its thickness. The block has at least one internal rib extending between said side walls at a point intermediate its height. The block also has cavity means in its top that is open to each of the open sides to receive block to block reinforcing means. Preferably, reinforcing means are embedded in the walls and top and bottom of the block. The base of the block can have a greater width than the top of the block to provide a greater thickness to the base of the block than the top and thereby facilitate the free standing of the blocks.

The invention will now be described by reference to the FIGURES, of which:

FIGS. 1 and 2 illustrate two designs of blocks of the invention;

FIG. 3 is a side view of another block design;

FIG. 4 is a view of a partially completed wall or fence using the blocks of the invention; FIG. 5 is a pilaster; and

FIGS. 6-9 illustrate blocks useful in building construction.

Referring now to FIG. 1, the invention comprises a block 10 having an open, hollow interior which is defined by bottom 12, top 14 and sidewalls 16 and 18. It is preferred to have at least one cross or internal rib 20 at a point intermediate the height of the block to impart support to the sidewalls and, as hereafter described, to provide support for reinforcement in walls, vertical panels, fences or the like constructed from the blocks. The sidewalls are smooth, unbroken surfaces and at least two sides of the block are open. With most of the blocks, the open sides will be opposite each other as shown in FIGS. 1 and 2.

The top 14 of the block bears cavity means 22 which can be in the form of a cylindrical bore through the width of the block. As described hereinafter in greater detail, cavity 22 receives block to block reinforcement means when the blocks are assembled into a unitary wall, vertical panel, fence of the like.

The block preferably bears internal reinforcement members within at least a portion of its walls. Various reinforcement members, typically of metal such as iron or aluminum or their alloys, e.g., mild steel, stainless steel, etc., can be used. The reinforcement can be in the shape of bars, rods, wire or cable. Woven wire reinforcement such as hardware cloth is shown at 24 and is embedded in wall 16. Preferably the reinforcement extends continuously around the block. A preferred material for the reinforcement is galvanized wire or cable.

The blocks are free standing and to impart stability to the blocks, it is preferred that the width of the base 12 be greater than that of top 14 so that the thickness of the block is greater at its base. This also will provide the block with an adequate thickness at its base so that the lower end or base of the block can be placed in a trench or the like to serve as a foundation or footing. The length of base 12 of the block is, of course, equal to the length of the top 14, with the exception, however, for comer blocks which are described hereafter with regard to FIG. 3.

FIG. 2 illustrates another form of a block of the invention. This block 24 has similar sidewalls l6 and 18 that extend between top 26 and bottom 28. One or more internal ribs 20 are provided at an intermediate height of the block. Typically, one rib can be provided at about the middle of the block; two ribs can be provided at equal or one-third spacings along the height of the block, etc. The bottom 28 does not extend the entire width of the bottom of block 28 and an open region is thereby provided. A groove 30 can be provided in the upper surface of bottom 28 as shown. This groove extends along the bottom, parallel to the sidewalls. This groove can be about 0.5 to about 2 inches in width and about the same dimension in depth and serves to hold or retain block to block reinforcement means when the blocks are assembled into a wall or the like.

The top 26 of block 24 is open and has a groove 32 which is similar in size, shape and alignment to groove 30. The top 26 could be flush with the top edges of walls 16 and 18 with only a single groove, however, it is preferred to have the edges of walls 16 and 18 extend slightly above top 26 in the manner in FIG. 2 to form an open channel when the blocks are assembled in which mortar, concrete or the like can be placed.

The grooves 30 and 32 serve to retain and align block to block retaining means such as steel rods. Mortar, concrete and the like can then be placed over the reinforcement means, filling the channel in the top of the block. The concrete can be placed to any desired depth in the open cell above bottom 28 and can be placed in the open cell over any of the internal ribs 20. The depth of the concrete that is placed in the interior of the blocks can be selected to provide the desired strength to the wall or like.

FIG. 3 illustrates another form of the block. In this form, side walls 32 and 34 are parallel. The base 36 of the block has a greater thickness than the remainder of the block and one or both of the sidewalls 32 and 34 can be stepped outwardly with ledge 38 extending to the offset base wall 40. A single groove 44 is provided in top 46 and the internal reinforcement, rods 48, which are shown by the broken lines, extends continuously around the block.

Internal ribs 50 and 52 extend between side walls 32 and 34 at intermediate heights to reinforce the walls and to serve. as ledges for supporting of mortar or concrete within the block. The lower rib 52 can extend only partially across the width of the block so that mortar or concrete can be readily placed within the open cell of base 36 after the blocks have been assembled into a wall or the like.

FIG. 4 illustrates'the construction of a wall using the blocks of this invention. A trench 56 is dug into the earth to the necessary depth to provide adequate support; in temperate climates to a depth of about 12 to 18 inches and to a depth below the normal frost line in colder climates. The blocks are placed vertically in the trench with their open sides in a side to side array and block to block reinforcement means such as the steel rods 58, 60 and 62 are extended through the open cells of the blocks, resting, respectively, in open cell 22, on internal rib and on bottom 12 of each block.

A corner block 64 is shown at the end of the wall. This block is, of course, somewhat different in construction in that it has two adjacent unbroken walls and two adjacent open walls. The two open walls are perpendicular to the base while the two closed walls are inclined in the manner shown in FIG. I for walls 16 and 18. The open cell 66 through the top 14 of the comer block also turns 90 degrees rather than extending through the block in a straight line so that reinforcement member 58 can be passed through thisv cell.

The fences, walls, vertical panels and the like are simply formed by placing the blocks together in a trench or on a previously prepared foundation or footing. The reinforcement members are placed in the continuous open cells formed by the alignment of these blocks and concrete, mortar or the like is placed in these open cells. The blocks are, of course, mortared together at their abutting sidewalls. The mortar or concrete can be placed in the open cells, about the reinforcement members as the wall is constructed, or it can be pumped into the open continuous cells after all or a portion of the wall or the like is constructed.

' It may be desirable to have, at periodical intervals along the length of the fence, wall or vertical panel, a block that can be filled entirely with concrete, mortar and the like. Often building codes will require the use of such blocks or pilasters. FIG. 5 illustrates a suitable pilaster that can be used with the blocks of this invention. The pilaster has four continuous sides l6, l7, l8 and 19 with a hollow core and is open at its top at 21. The base is also open and an aperture 13 is provided through two opposite side walls 17 and 19 to permit passing of the reinforcement through the block. The open base of the block permits pouring of concrete into a hole or trench beneath the block so that the footing beneath this block can be made considerably deeper than the remainder of the wall, e.g., from 16 to 36 inches in depth, as desired.

The walls of the pilaster can be reinforced with internal ribs which are not continuous across the cross section of the block. A view of suitable ribs is shown by 21 which extends about the inner periphery of the block and which has an internal steel reinforcement, wire or cable 23. A plurality of these at varied heights can be used in the construction of block 11.

The aforedescribed blocks with minor variations can be used to form the walls of buildings and the like. FIGS. 6 through 9 illustrate such blocks. Block 65 shown in FIG. 6 has a top 66 with a cavity 63 similar to that described with regard to the block of FIG. 2 with a groove 32 for placement of reinforcement. The base 67 of the block has a greater thickness than the remainder of the block and side wall 68 is shown stepped outwardly by inclined wall 69. The side walls 68 and 70 are continuous with a plurality of internal ribs 71 and 72 that extend between the walls. The base of the block is hollow with a bottom wall that bears a groove 73 for placement of reinforcement steel. This bottom wall is shown as extending the entire width of the block, however, it could be narrower and similar in construction to the bottom wall 28 shown in FIG. 2, if desired.

The inclined side wall 69 bears an aperture 74. When the block is placed in the correct alignment for formation of a building wall, its base will be beneath the ground level so that it will form the footing for the wall. Thereafter, concrete or the like can be poured into the hollow footing formed by the side by side array of these blocks through the apertures 74. This footing, which will be reinforced with steel rods, wire, cable and the like, will be continuous and integral with the side by side array of wall blocks 65. The blocks can also be used to form the perimeter of the floor and the entire floor and footing can be poured in a single operation after the block have been placed in a trench about the perimeter of the building. The concrete to form the footing will flow into the hollow bases of the blocks through apertures 74 and the floor can be poured to a level at the juncture of the inclined wall 69 and wall 68.

FIG. 7 illustrates a suitable pilaster that can be used with blocks such as 65 to provide periodic reinforcement to the resulting wall. The pilaster has four continuous walls which have internal ribs 23 with reinforcement 21 similar to those described with regard to FIG. 5. The ribs are open so that the entire interior of the block 76 and the top of the block is open at 77. The remainder of the block is similar in shape and construction to block 65 with the exception that apertures 78 are provided through the base of two of its sides to permit passing of reinforcement steel through the base of the block. Similar apertures can be provided as desired at various heights of the block for placement of reinforcement steel throughout the height of the wall.

FIG. 8 illustrates another block that can be used for building construction. This block has both sidewalls, 81 and 82 inclined slightly outwardly with inclined walls 83 and 84 to provide a base of greater thickness than the remainder of the wall block 80. Provision can be made in the sidewall of some of the blocks to support joists for floors. This is shown by notch 85 at an intermediate height of the block. This notch is of suitable dimensions to accomodate wood beams, e.g., approximately 1 to 3 inches in depth and from 4 to about 12 inches in height. The top and bottom of the notch can be strengthened by ribs 86 and 88 that extend across the block and the side of the notch can be strengthened by a vertical rib 89. The entire support for a single joist can be placed within one block by a notch of sufficient depth, or each block of a pair of mating blocks can be provided with a notch of approximately 9% the necessary depth for the joist, and these blocks can be assembled in side to side array in the manner shown in FIG. 8.

The base of block 80 is provided with an aperture 90 in the inclined side wall 83 to permit concrete to flow into the base and fill cavity 91 when the floor or footing is poured. Alternatively, concrete could be pumped into the hollow base of the block after a plurality of block had been assembled into a side to side array'for formation of the wall.

To provide flexibility for the construction of varied building styles it is desirable to provide means for extending the height of the blocks. This would permit the use of the blocks for the construction of buildings with inclined rather than flat roofs. FIG. 9 illustrates interconnecting means that can be provided in the blocks. The view shows the top portion of a block 95 which has its opposite side walls 96 and 97 extending slightly above the top rib 98. An internal brace 99 extends between the upper ends of these walls and a notch 100 is provided at about the mid portion of this brace. The brace 99 can extend to the top of walls 96 and 97 if desired. The upper block 101 that fits on top of this block 95 has a plurality of legs or brackets 102 and 103 dependent from its under surface. These brackets also have a central notch 104 which, when the blocks are fitted together, will be in alignment with the notch 100 of bracket 99. The notches function to align reinforcement steel during assembly of the blocks which are placed together with mortar and the like placed between side walls 96 and 97 to cement the blocks together.

The blocks of FIGS. 6-9 are of a suitable height for building walls. The floor to ceiling distance of these walls is generally from 7 to about 9 feet and the footing is from 1 to about 3 feet. Accordingly. the blocks are from 8 to about 12 feet in height. The width of the base portion of the blocks can be from about inches to about 16 inches, preferably about 12 inches. The thickness of each block in the wall section can be from about 4 to about 9 inches. The width of each block can be from about 4 to about 12 inches, preferably about 8 inches.

The blocks of this invention can be used for the construction of walls, fences, vertical panels and the like without requiring the high degree of skill necessary for the formation of typical masonry walls where a plurality of horizontal courses of blocks are used. The blocks of this invention can be simply assembled in a side to side array and in this assembly can be accurately observed for correct alignment before the concrete or mortar is placed in the blocks. The blocks serve as forms for the concrete that is placed therein as well as forms for the floor of the building when the blocks of the type of FIGS. 6-9 are used.

The invention has been described with reference to the presently preferred modes of practice thereof. It is not intended that the illustrated and preferred modes of practice be unduly limiting of the invention. Instead, it is intended that the invention be defined by the elements and their obvious equivalents set forth in the following claims.

I claim:

1. A vertical wall panel of from 8 to 12 feet in height with a wall thickness of from 4 to 9 inches and a base of greater thickness, from 10 to 16 inches, positioned in a trench in the earth, said wall panel being formed of: (l) a plurality of blocks; each block of which has a height from 8 to 36 times its thickness, extending the entire height of said panel, and formed by bottom and top walls with two sidewalls extending therebetween to define a hollow core body having parallel interior and exterior surfaces and two, entirely open sides, at least one internal rib substantially parallel to said bottom and top walls and fully extending between said sidewalls at an intermediate level of said block to divide its hollow core body into at least two through openings and cavity means in the top thereof separated from said through openings; said blocks resting with their bottom surfaces on the bottom of said trench and having their open sides in joined side to side array to interconnect the cavities and respective through openings thereof and thereby form a plurality of continuous horizontal cells extending the length of said panel, (2) horizontal metal reinforcing means extending continuously along said panel in each of said continuous horizontal cells and (3) concrete filled in said continuous horizontal cells above and about said reinforcing means.

2. The vertical wall panel of claim 1 including reinforcing means embedded within said sidewalls of each of said blocks.

3. The vertical wall panel of claim 1 wherein said cavity means in the top of said blocks is enclosed and extends between said two open sides.

4. The vertical wall panel of claim 1 wherein said cavity means in said top comprises a groove in said top, generally parallel to said sidewalls, and said top, comprises a transverse rib extending the entire width of said block to separate said groove from said through openings.

5. The vertical wall panel of claim 1 wherein said said side walls are smoothly tappered between the top of said wall and said base of greater thickness.

6. The vertical wall panel of claim 1 wherein said side walls are substantially parallel.

7. The vertical wall panel of claim 1 wherein at least one of said side walls has a stepped portion projecting to said base of greater thickness.

8. The vertical wall panel of claim 1 wherein the height of each of said blocks is from 12 to 24 times its average thickness.

9. The vertical wall panel of claim 1 wherein a portion of one of the side walls of each of said blocks inclines outwardly to said stepped portion of greater width and bears an aperture whereby plastic material poured about the base of said block will flow through said aperture and into the continuous horizontal cell 7 8 formed by the interconnected hollow base of said top and bottom at the lower extremities thereof to enblocks' close said continuous horizontal cell formed by the in 10. The vertical wall panel of claim 9 wherein each of said blocks bears a second internal rib extending between said opposite side walls generally parallel to said terconnected hollow bases of said blocks. 

1. A vertical wall panel of from 8 to 12 feet in height with a wall thickness of from 4 to 9 inches and a base of greater thickness, from 10 to 16 inches, positioned in a trench in the earth, said wall panel being formed of: (1) a plurality of blocks; each block of which has a height from 8 to 36 times its thickness, extending the entire height of said panel, and formed by bottom and top walls with two sidewalls extending therebetween to define a hollow core body having parallel interior and exterior surfaces and two, entirely open sides, at least one internal rib substantially parallel to said bottom and top walls and fully extending between said sidewalls at an intermediate level of said block to divide its hollOw core body into at least two through openings and cavity means in the top thereof separated from said through openings; said blocks resting with their bottom surfaces on the bottom of said trench and having their open sides in joined side to side array to interconnect the cavities and respective through openings thereof and thereby form a plurality of continuous horizontal cells extending the length of said panel, (2) horizontal metal reinforcing means extending continuously along said panel in each of said continuous horizontal cells and (3) concrete filled in said continuous horizontal cells above and about said reinforcing means.
 2. The vertical wall panel of claim 1 including reinforcing means embedded within said sidewalls of each of said blocks.
 3. The vertical wall panel of claim 1 wherein said cavity means in the top of said blocks is enclosed and extends between said two open sides.
 4. The vertical wall panel of claim 1 wherein said cavity means in said top comprises a groove in said top, generally parallel to said sidewalls, and said top, comprises a transverse rib extending the entire width of said block to separate said groove from said through openings.
 5. The vertical wall panel of claim 1 wherein said said side walls are smoothly tappered between the top of said wall and said base of greater thickness.
 6. The vertical wall panel of claim 1 wherein said side walls are substantially parallel.
 7. The vertical wall panel of claim 1 wherein at least one of said side walls has a stepped portion projecting to said base of greater thickness.
 8. The vertical wall panel of claim 1 wherein the height of each of said blocks is from 12 to 24 times its average thickness.
 9. The vertical wall panel of claim 1 wherein a portion of one of the side walls of each of said blocks inclines outwardly to said stepped portion of greater width and bears an aperture whereby plastic material poured about the base of said block will flow through said aperture and into the continuous horizontal cell formed by the interconnected hollow base of said blocks.
 10. The vertical wall panel of claim 9 wherein each of said blocks bears a second internal rib extending between said opposite side walls generally parallel to said top and bottom at the lower extremities thereof to enclose said continuous horizontal cell formed by the interconnected hollow bases of said blocks. 